Cable end holder thingys

[ken will]

It is easy to make cable end holders out of 1" tubing.

Step 1: Come down 1/4" and in 1/4" and set a dimple with your center punch.
Step 2: Drill all the way through with a 1/16" bit.
Step 3: Drill just the top with a 3/16" bit

http://elrgjw.blu.livefilestore.com/y1pZUlbCdUyoiJaSd1lK7JFxzKN49I4rcfPRBuqJwfzN23kFsg 0J80igEtWSI0OahRnXzZ10fjjwAR0C5zM-Hot0Mbdnq6_kznc/A.jpg

Step 4: Cut down the middle 1/2"
Step 5: Cut across - notice the left side has 2 extra holes, that's for the alternate method.
Step 6: Check you cable for fit.
Step 7: Use a hose clamp to hold it steady while you file it down to dress it up.

http://elrgjw.blu.livefilestore.com/y1pmSMyYCmxxJOljwiOQFetfG7ziOAtusIqOrQuoySKZZK9AtD Tq8w3pvX9nvOkT5QJr1zy6nrh3HocfGFm9iD1FMtjXh4FCsbk/B.jpg

Step 8; Weld better it than I did.

http://elrgjw.blu.livefilestore.com/y1pQCYwTF18Qc-24FBSD1uejO97yD2D0BL-oOTilLJRm-G7BXfEB9qMzjJj4eOK10laTR0TXUwkT-th3nQfuOeXdnJzJrbSDk-W/C.JPG

An Alternate method is to "Plunge Weld" which is similar to spot welding.

Plunge 1: Remember the one on the left with 2 extra holes, hole it in position and mark where the 2 holes go.
Plunge 2: Scrape off the paint just where you marked it.
Plunge 3: Plunge your stick or wire into the hole and give it a little zap.
Plunge 4: It should look something like this.

http://elrgjw.blu.livefilestore.com/y1p49shws6eSutyCc0BP3OnY1KHlq04gnhER-aAJFsebJRassKDIvkfO6yiIk_sO-lfKgS_fSPCxIaiT2AmpnT6r7IMVX3-5rP2/D.jpg

After a few Minutes of filing the first method looks like the one on the left.
After a few Seconds of filing the plunge method looks like the one on the right, the paint didn't even get melted.

http://elrgjw.blu.livefilestore.com/y1p3IlBv1fVg3Sihq2wh2SS9vXgs4CFdENleThaBJXzayKURfX 46OTSqesbmTsYLpUtwJODez1iuKpu2uONe7LdQdA4iZrhpHid/E.JPG

[Patrike]

That is very innovative - but to me it is easier to buy aluminum rivot on's for $1.00 or cut them off other scrap bikes bikes and reuse. But good to know if your in a pitch or on a really tight budget. Probably 1/2 tube would do as well. Thanks for sharing.

[TheKid]

Probably 1/2 tube would do as well.

1/2" would be closer to the size of braise-ons. I like this. Looks like you could cut quite a few in a short amount of time. I'll try it tomorrow with 1/2" tubing that I'd like to get rid of. I'd highly recommend using step down ferrules to avoid abrasion:

http://www.biketoolsetc.com/index.cgi?id=69760313631&d=single&c=Cable-Housing&sc=Ferrules&tc=5mm&item_id=JW-1156/10

[TheKid]

Fantastic idea Ken. Thanks for sharing.
I used 1/2" as Pat said, just to see how things would work out. I drilled a bunch of holes on one side to accept the ferrule, and the other side the next size larger on the step drill. I didn't measure, so it took less tha 5 minutes to drill them out. Add a few minutes if you want to be more exact. Some of them were made with the larger hole on each side in case I need some just to hole the cable in place. A couple are very close together in case I need a double. The larger hole is a bit too large, so next time I'll just file them out. I did use a file in each hole just to soften the edge. The first pic shows the hole drilled.

http://i192.photobucket.com/albums/z66/edpol_photos/cable%20stops/100_0296Small.jpg

No need to cut each one off, just clamp the whole thing to the frame and cut it off later.

http://i192.photobucket.com/albums/z66/edpol_photos/cable%20stops/100_0297Small.jpg

The welds are cleaned. A little spot putty here would make it perfect, but no sense wasting it on a scrap experimental piece, since I don't have much left.



http://i192.photobucket.com/albums/z66/edpol_photos/cable%20stops/100_0298Small.jpg

It would look better painted if the scrap frame was in better shape.

http://i192.photobucket.com/albums/z66/edpol_photos/cable%20stops/100_0300Small.jpg

It took less than a half hour to get this far.
More to come tomorrow. Right now, my seat foam was just delivered, so I'll work on the new Fox seat.